CN119631010A - Functionalized optical layered structure, functionalized optical article, eyewear containing functionalized optical article, and method for making the same - Google Patents
Functionalized optical layered structure, functionalized optical article, eyewear containing functionalized optical article, and method for making the same Download PDFInfo
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- CN119631010A CN119631010A CN202380052941.7A CN202380052941A CN119631010A CN 119631010 A CN119631010 A CN 119631010A CN 202380052941 A CN202380052941 A CN 202380052941A CN 119631010 A CN119631010 A CN 119631010A
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- G—PHYSICS
- G02—OPTICS
- G02C—SPECTACLES; SUNGLASSES OR GOGGLES INSOFAR AS THEY HAVE THE SAME FEATURES AS SPECTACLES; CONTACT LENSES
- G02C7/00—Optical parts
- G02C7/10—Filters, e.g. for facilitating adaptation of the eyes to the dark; Sunglasses
- G02C7/108—Colouring materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D11/00—Producing optical elements, e.g. lenses or prisms
- B29D11/00009—Production of simple or compound lenses
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D11/00—Producing optical elements, e.g. lenses or prisms
- B29D11/00009—Production of simple or compound lenses
- B29D11/00432—Auxiliary operations, e.g. machines for filling the moulds
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D11/00—Producing optical elements, e.g. lenses or prisms
- B29D11/0073—Optical laminates
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/20—Filters
- G02B5/22—Absorbing filters
- G02B5/223—Absorbing filters containing organic substances, e.g. dyes, inks or pigments
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- Engineering & Computer Science (AREA)
- Health & Medical Sciences (AREA)
- Ophthalmology & Optometry (AREA)
- Physics & Mathematics (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- General Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- General Health & Medical Sciences (AREA)
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Abstract
一种功能化光学层状结构、功能化光学制品、包含功能化光学制品的眼睛配戴物、及其制造方法。一种功能化光学层状结构包括：‑第一元件，该第一元件表示第一单层或多层功能膜(15)；‑至少一个第二元件，该至少一个第二元件选自保护衬垫层、或基底光学元件(1)、或第二功能膜‑至少一个压敏粘合剂层，该至少一个压敏粘合剂层被放置成与所述第一元件的至少一个表面和所述第二元件的至少一个表面接触，其中，至少一个压敏粘合剂层(14')具有光学质量并且包括上色剂(12)。
A functionalized optical layered structure, a functionalized optical article, an eyewear containing the functionalized optical article, and a method for manufacturing the same. A functionalized optical layered structure comprises: a first element, the first element representing a first single-layer or multi-layer functional film (15); at least one second element, the at least one second element selected from a protective backing layer, or a base optical element (1), or a second functional film; at least one pressure-sensitive adhesive layer, the at least one pressure-sensitive adhesive layer being placed in contact with at least one surface of the first element and at least one surface of the second element, wherein the at least one pressure-sensitive adhesive layer (14') has optical quality and comprises a colorant (12).
Description
Technical Field
The present invention relates to a functionalized optical layered structure, a functionalized optical article, an eyewear comprising a functionalized optical article, and methods of making the same.
Background
The process of preparing a functionalized optical layered structure, such as an ophthalmic tinted lens, includes several methods of manufacture.
As known in the art, lenses are typically tinted by introducing a colored additive into the molten glass, and similarly polycarbonate lenses are injection molded from pre-tinted plastic particles. A disadvantage associated with these methods is the very limited flexibility in the range of colors that can be provided. In addition, when colored by this method, lenses of widely varying thickness also exhibit non-uniform transmittance.
Conventionally, the dip dyeing method has been used as one of dyeing methods for dyeing plastic lenses of spectacles in most cases. The dip dyeing method includes preparing a dyeing solution by mixing disperse dyes of three primary colors of red, blue and yellow and dispersing the mixture in water, heating the dyeing solution to about 90 ℃, and immersing a plastic lens in the heated solution, thereby dyeing the lens.
As an alternative to the dip dyeing method, a vapor deposition or sublimation dyeing method has been proposed, for example, as disclosed in document JP-a-01 277 814. The method includes heating a sublimable solid dye under vacuum to sublime the solid dye and vapor deposit the sublimed dye onto a plastic lens while heating the plastic lens under vacuum to dye the lens.
More precisely, as disclosed in fig. 1a to 1c, this sublimation method comprises a sublimation step (fig. 1 a) during which the optical substrate element 1 is arranged in a sublimation enclosure 2, wherein a sublimable colorant 3 pre-printed on the surface of a paper support 4 and facing the optical substrate element 1 is sublimated and then deposited on a facing surface 6 of the optical substrate element 1, which results in the assembly illustrated in fig. 1b, wherein the upper surface 6 of the optical substrate element 1 is covered with the sublimated colorant 3.
Another step that occurs in the imbibition enclosure depicted in fig. 1c involves fixing the colorant on the surface of the optical substrate element by exposing the assembly 1,3 to heat for a sufficient period of time to allow the colorant to be fixed to the surface and/or thickness of the substrate element. This method is particularly popular because less waste of colorant is produced than less sustainable methods such as the dip-tinting method described above, without using more colorant than is needed, simply by printing the colorant on paper, then sublimating and fixing it to the lens.
However, depending on the chemistry of the optical base element 1, the imbibition step may last more than one hour or even several hours, effectively fixing the colorant to/penetrating the lens. Furthermore, due to this relatively large imbibition time and temperature, some already functionalized optical substrate elements cannot withstand this method of tinting, but need to be tinted with alternative solutions such as dip tinting processes, which are known to be less sustainable. In addition, for curved optical substrate elements, as depicted in fig. 1c, the colorant is typically deposited on the concave surface instead of its convex surface, so as to avoid any migration of sublimated colorant towards the periphery of the optical substrate element, which migration would occur when the colorant is deposited on the convex side. Furthermore, during the imbibition step, the obtained coloured optical base element is then turned over so that its coloured concave side faces the bottom surface of the imbibition box, any migration of the colouring agent to the centre of the lens during the imbibition step being now avoided, thus avoiding the creation of unwanted colour gradation (fig. 1 c). With this arrangement, it is then often observed that some wasted toner is deposited on the bottom base of the suction enclosure rather than being fixed to the concave surface of the optical substrate element. This means that for a given target lens color, a slightly greater amount of colorant will need to be printed, taking into account the colorant waste 3' that occurs during the imbibition step.
Thus, both the dip dyeing method and the conventional sublimation dyeing method have a disadvantage of not being able to provide a stable dyed lens. In particular, it is difficult to dye lenses with low dyeability, or to dye lenses with dark colors or colors with high density. In the case of both sublimation and immersion tinting methods, the likelihood of tinting an already functionalized lens is even less.
On the other hand, the optical article may be provided with additional functionalized structures composed of single-layer or multi-layer structures, which may be laminated onto and adhered to the optical substrate element to provide specific functionalities, such as scratch resistance, polarization.
However, in this case, if the optical article has to be colored, it is the optical substrate element that needs to be colored, which avoids the later hue difference, or it is one of the functional layers of the additional functionalized structure that needs to be colored, which requires the above-mentioned relatively time-consuming coloring method and/or the use of relatively large amounts of dye to bring the deepest optical article to the target hue to be obtained.
Thus, there is a substantial need for new methods that are industrially effective for tinting optical lenses that will not suffer from the drawbacks of the prior art systems.
Disclosure of Invention
According to the present disclosure, the object is achieved by a functionalized optical layered structure comprising:
-a first element representing a first single-layer or multi-layer functional film;
At least one second element chosen from a protective backing layer, or a base optical element, or a second functional film
-At least one pressure sensitive adhesive layer placed in contact with at least one surface of the first element and at least one surface of the second element and having optical quality and comprising a colouring agent.
The fact that the pressure sensitive adhesive layer is a material comprising a colorant has the advantage that the time required for fixing the colorant and the amount of colorant required to reach a specific hue are reduced compared to the time and amount of dye required when sublimating the colorant on a plastic lens and even compared to methods in which a substrate element or functional layer of a multilayer structure needs to be dyed. Another benefit is the possible late differentiation and the possibility of defining a one-piece flow process due to the speed of the process.
Advantageously, the colorant comprises a sublimable, printable, sprayable or ink-jettable colorant.
Preferably, the second element is a base optical element and the at least one pressure sensitive adhesive layer defines a peel force when dry and a peel force when wet, each greater than 13N/25mm to separate the first element from the second element.
More preferably, the pressure sensitive adhesive layer (14') has a reduction between the peel force upon drying and the peel force upon wetting of not more than at least 35%.
According to an advantageous embodiment, the pressure sensitive adhesive layer exhibits a storage modulus G' at 85 ℃ lower than 1.6x10 5 Pa, preferably lower than or equal to 1.5x10 5 Pa, and the pressure sensitive adhesive layer exhibits a dry peel strength and a wet peel strength both higher than 20N/25mm, preferably both in the range of 21N/25mm to 40N/25mm, inclusive.
According to yet other aspects of the invention, the functionalized optical layered structure may comprise any of the following features considered alone or in combination with each other and/or with the above features:
These colorants include sublimable, printable, sprayable or ink-jettable colorants,
The at least one pressure sensitive adhesive layer has a thickness ranging from 5 μm to 150 μm or more,
The pressure sensitive adhesive material is selected from polyacrylate based compounds,
The first element represents a functional film comprising at least one function selected from the group consisting of color, polarization, photochromism, electrochromic, impact resistance, abrasion resistance, antistatic, antiglare, antifouling, antifogging, rainproof, interference coating (such as an antireflection coating or a specular coating), dichroic filter, and spectral filter over a specified wavelength band.
The present invention relates to a functionalized optical article comprising a base element and a functionalized optical layered structure applied on one surface of said base element, the functionalized optical layered structure comprising:
-a first element representing a first single-layer or multi-layer functional film;
At least one second element chosen from a protective backing layer, or a base optical element, or a second functional film
-At least one pressure sensitive adhesive layer placed in contact with at least one surface of the first element and at least one surface of the second element, wherein the at least one pressure sensitive adhesive layer has optical quality and comprises a colorant.
Advantageously, the functionalized optical layered structure of the functionalized optical article may comprise any combination of the features of the functionalized optical layered structure described above.
According to another aspect, the invention relates to an eyewear device comprising a support structure, such as a frame, and at least one functionalized optical article intended to be enclosed within the support structure and edged according to the dimensions of the support structure, said functionalized optical article comprising a base element and a functionalized optical layered structure applied on said base element, the functionalized optical layered structure comprising:
-a first element representing a first single-layer or multi-layer functional film;
At least one second element chosen from a protective backing layer, or a base optical element, or a second functional film
At least one pressure sensitive adhesive layer placed in contact with at least one surface of the first element and at least one surface of the second element,
The at least one pressure sensitive adhesive layer has optical quality and includes a colorant.
According to an embodiment of the eyewear device, the different layers of the base element of the edging functionalized optical article adhere to each other or do not have any bubbles or peeling between successive layers through the entire edging surface and up to the edge of the optical article.
Preferably, the functionalized optical layered structure of the eyewear device may include any combination of the features of the functionalized optical layered structure described above.
The invention also relates to a method of manufacturing a functionalized optical layered structure, the method comprising the steps of:
-providing a functionalized optical layered structure comprising:
A first element representing a first single-layer or multi-layer functional film
At least one pressure-sensitive adhesive layer, wherein the at least one pressure-sensitive adhesive layer has optical quality
-Coloring at least one surface of the at least one pressure sensitive adhesive layer with a coloring agent.
Desirably, the step of coloring the at least one pressure-sensitive adhesive layer is a sublimation step, the colorant is sublimable, and during the sublimation step, the at least one pressure-sensitive adhesive layer is in a flat form, and the colorant transfer support facing the at least one pressure-sensitive adhesive layer is in a flat form. Alternatively, the at least one pressure sensitive adhesive layer may not be planar (i.e., curved) if the consumable incorporating the at least one pressure sensitive adhesive layer is in a preformed or curved configuration.
In this case, the distance between the toner transfer support and the at least one pressure-sensitive adhesive layer is less than 15mm, preferably less than 12mm and preferably more than 5mm.
According to an embodiment of interest, the method further comprises a bleeding step to fix the colorant to the at least one pressure sensitive adhesive layer after the coloring step.
In this case, it is advantageous that, during the imbibition step, at least one pressure-sensitive adhesive layer is arranged such that the surface of the at least one pressure-sensitive adhesive layer on which the colorant is deposited constitutes the upper surface of the at least one pressure-sensitive adhesive layer.
More preferably, the imbibition step comprises heating the at least one pressure-sensitive adhesive layer at a temperature and for a time that allows softening without melting the at least one pressure-sensitive adhesive layer, for example at a temperature below 1 hour and below 90 ℃, preferably at a temperature below 10 minutes and below 90 ℃, such that the colorant is immobilized on the surface of the at least one pressure-sensitive adhesive layer and/or penetrates the thickness of the at least one pressure-sensitive adhesive layer.
Advantageously, the heating step comprises heating the at least one pressure sensitive adhesive layer by air convection or by surface irradiation (e.g. irradiation with IR/UV laser).
The method of manufacturing the functionalized optical layered structure may comprise any of the following features considered alone or in combination with each other and/or with the above features:
a step of coloring the at least one pressure-sensitive adhesive layer with a coloring agent is performed before the step of placing the at least one pressure-sensitive adhesive in contact with the at least one surface of the second member,
The colorant is a sublimable, printable, sprayable or ink-jettable colorant, and wherein the step of coloring the at least one pressure sensitive adhesive layer is correspondingly a step of subliming, printing, spraying or ink-jetting the colorant on the at least one pressure sensitive adhesive layer,
-Subjecting the surfaces of the first and second elements intended to be placed in contact with the at least one adhesive layer to a surface treatment before the contact placement selected from a plasma treatment in an inert nitrogen atmosphere at a dose ranging from 40W-min/m 2 to 100W-min/m 2 and a corona treatment in ambient air at a dose ranging from 40W-min/m 2 to 50W-min/m 2 such that the reduction between the peel force under dry conditions and the peel force under wet conditions is less than or equal to 35% (inclusive).
According to a possible embodiment, the PSA supported between two protective liner layers may also be colored. After the PSA is pigmented, it can be applied to a first element in the form of a functional film and then to a second element in the form of an optical substrate element.
The invention also relates to a method of manufacturing a functionalized optical article, the method comprising:
-a step of thermoforming a functionalized optical layered structure according to a curvature of a base element of the base element, the functionalized optical layered structure comprising:
a first element representing a first single-layer or multi-layer functional film;
At least one second element selected from a protective backing layer or a second functional film
At least one pressure sensitive adhesive layer placed in contact with at least one surface of the first element and at least one surface of the second element, wherein the at least one pressure sensitive adhesive layer has optical quality and comprises a colorant
-A step of fixing the thermoformed ophthalmic functional film structure on the base element.
Preferably, the functionalized optical layered structure of the above-described manufacturing method may comprise any combination of the features of the functionalized optical layered structure described above.
According to another aspect, the invention relates to a method of manufacturing an eyewear device, the method comprising:
-a step of thermoforming an ophthalmic functional film structure according to the curvature of the base element, the ophthalmic functional film structure comprising:
a first element representing a first single-layer or multi-layer functional film;
At least one second element selected from a protective backing layer or a second functional film;
At least one pressure sensitive adhesive layer placed in contact with at least one surface of the first element and at least one surface of the second element, wherein the at least one pressure sensitive adhesive layer has optical quality and comprises a colorant;
-a step of fixing the thermoformed ophthalmic functional film structure on the base element, and
-A step of edging the thermoformed ophthalmic functional film structure applied on the base element according to the dimensions of the support structure.
Drawings
For a more complete understanding of the description provided herein, and the advantages thereof, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts.
Figures 1a to 1c already mentioned illustrate successive steps of manufacturing a functionalized optical layered structure according to the prior art,
Fig. 2a to 2g show successive steps of manufacturing a functionalized optical layered structure according to the invention, fig. 2g shows two embodiments of a functionalized optical article obtained when the functionalized optical layered structure is arranged on a concave side (fig. 2g. Alpha.) and a convex side (fig. 2g. Beta.) of an optical base element,
Figure 3 schematically shows a functionalized optical layered structure according to the invention,
Figure 4 shows a graph with a histogram showing the peel force of different PSA layers (with or without a colorant) for different imbibition times under wet conditions (black symbols) and dry conditions (white symbols).
Detailed Description
In the following description, the drawings are not necessarily to scale and certain features may be shown in generalized or schematic form in the interest of clarity and conciseness or for information purposes. In addition, while the making and using of various embodiments are discussed in detail below, it should be appreciated that numerous inventive concepts may be provided herein that may be practiced in a wide variety of contexts. The embodiments discussed herein are merely illustrative and do not limit the scope of the invention. It is also obvious to a person skilled in the art that all technical features defined with respect to the method can be transposed to the apparatus individually or in combination, whereas all technical features defined with respect to the apparatus can be transposed to the method individually or in combination.
To avoid unnecessary detail to enable the invention, the description may omit certain information known to those skilled in the art.
Detailed Description
Although representative methods and apparatus have been described in detail herein, those skilled in the art will recognize that various substitutions and modifications can be made without departing from the scope described and defined by the appended claims.
Optical article/optical (substrate) element
According to the invention, the optical article comprises at least one pressure sensitive adhesive layer having optical quality and comprising a colorant, and the at least one pressure sensitive adhesive layer is placed in contact with at least one surface of the first element and at least one surface of the second element.
The fact that the pressure sensitive adhesive layer is a material comprising a colorant has the advantage of reducing the time required for fixing the colorant and the amount of colorant required to reach a specific hue compared to the time and amount of dye required when sublimating the colorant on a plastic lens as is the case with the conventional method illustrated in fig. 1a to 1 c.
More precisely, for the purposes of the present invention, an optical article is considered transparent when viewing an image through this element is perceived without significant loss of contrast. Unless otherwise indicated, the intervention of transparent optical elements between the image and the image viewer does not significantly reduce the image quality. In the ophthalmic field, this definition is considered to be satisfied when the optical element has a haze of not more than 1, preferably not more than 0.4. Within the meaning of the present invention, this definition of the term "transparent" applies to all objects thus regarded in the present specification.
An optical article is defined herein as one of an ophthalmic element/lens, a eye shield, and a vision optical system. Non-limiting examples of ophthalmic elements include corrective and non-corrective lenses, including single-or multi-optic lenses, which may be segmented or non-segmented, as well as other elements for correcting, protecting or enhancing vision, including but not limited to magnifying lenses and protective lenses or goggles, such as found in eyeglasses (spectacles), glasses (glasses), sunglasses, swimming goggles (goggles), and helmets.
The optical article is composed of an optical substrate element coated with a functional structure, both of which are described below.
The optical substrate element may be a standard component selected from the group consisting of an optical lens, a window, a goggle, preferably an optical lens, more preferably an ophthalmic lens.
The optical substrate element may be selected from the group consisting of a finished lens, a semi-finished lens, a progressive addition lens, an afocal lens, a plano lens, a monofocal lens, and a multifocal lens.
Semi-finished lenses (SF) refer to lenses having one optical surface and another surface that requires grinding according to the wearer's prescription.
The optical substrate element may be made of any material that is classically used in optical devices. In particular, the optical substrate element is made of a plastic, which may be a thermoplastic or a thermosetting material. Examples of plastics include polycarbonates, polyamides, polyimides, polysulfones, copolymers of polyethylene terephthalate and polycarbonates, polyolefins, i.e., polynorbornenes, polymers and copolymers of diethylene glycol bis (allyl carbonate), polymers and copolymers of (meth) acrylic acid, i.e., polymers and copolymers of (meth) acrylic acid derived from bisphenol-A, thio (meth) acrylic acid, urethane and thiourethane polymers and copolymers, epoxy polymers and copolymers, and episulfide polymers and copolymers. In a preferred embodiment, the optical substrate element is made of polycarbonate or high refractive poly (thio) urethanes with a light refractive index between 1.60 and 1.67 or episulfide with a light refractive index between 1.60 and 1.67. More preferably, the optical substrate element is made of a (thio) urethane based prepolymer or an episulfide monomer.
Functional film structure
The functional film structure is composed of the following components:
a single-layer or multi-layer structure supported by an optional support film or carrier,
At least one pressure sensitive adhesive layer (PSA layer) of optical quality to permanently retain the functional film structure on the surface of the optical substrate element,
A releasable protective backing layer, one of which is in direct contact with the surface of the PSA layer and a second of which is in direct contact with the single-layer, multi-layer structure or support film of the functional film structure.
Preferably, the support film is made of cellulose Triacetate (TAC) and has a thickness of at least 40 micrometers, preferably has a thickness in the range of 40 to 300 micrometers, and preferably has a thickness of 80 to 190 micrometers. The material of the support film may be selected from the group of films made of cellulose Triacetate (TAC), cellulose Acetate Butyrate (CAB), polycarbonate (PC), poly (ethylene terephthalate) (PET), poly (methyl methacrylate) (PMMA), urethane polymers (TPU), cyclic Olefin Copolymers (COC), polyester block copolyamides (like Pebax) and polyimides.
The functional film structure useful in the present invention includes at least one functional film or one single layer structure. In other words, the functional film structure may comprise one or more functional films, which may comprise different functions.
Various types of functional films may be employed. Examples of the functional film include a coloring film, a polarizing film, a photochromic film, a hard coat film, a top coat film, an antifogging film, an antifouling film, an antireflection film, and an antistatic film. The functional film may have a single-layer or multi-layer structure. In other words, it refers to a single functional film or layered structure comprising at least one support film and one or more individual functional layers (coatings or films) adhered together with the same or different properties. Thus, according to one embodiment, the functional film may comprise a support film adapted to be adhered or fixed to the optical substrate element by means of an adhesive layer.
The different functional films, if any, may adhere to each other due to surface treatment and/or an adhesive, a preferred option of which in the optical element and ophthalmic fields is the pressure sensitive adhesive category.
However, when the functional film structure comprises a multilayer layer structure having several PSA layers, the PSA layer to be coloured according to the invention is preferably constituted by a PSA layer in direct contact with one of the two releasable liner layers, since it is easier to reach after simple removal of the protective liner layer than the other PSA layer. However, other PSA layers may also be pigmented according to the invention.
Furthermore, when the functional film structure contains a single layer structure, the PSA layer surface to be colored according to the present invention is constituted by the PSA layer surface in direct contact with one of the two releasable liner layers, because it is easier to reach after removal of the protective liner layer.
Preferred embodiments of functional film structures that can be used in the present invention can include those disclosed in patent application US2016/0216425 from the applicant and incorporated herein by reference or those disclosed in patent application WO 2020/002606 also from the applicant and incorporated herein by reference and illustrated in fig. 3.
PSA pressure sensitive adhesives "
"Pressure sensitive adhesive" refers to a dry contact adhesive having viscoelastic properties that requires only very slight pressure to adhere to the surfaces between which it is located.
"Pressure-sensitive adhesive layer" refers to a layer made of a pressure-sensitive adhesive, or to a layer made of a pressure-sensitive adhesive. Pressure sensitive adhesives are characterized by their ability to exert strong adhesive retention on surfaces without requiring activation by water, solvents or heat.
The pressure sensitive adhesive may be obtained in the form of a continuous layer made of a pressure sensitive adhesive composition (i.e., a pressure sensitive adhesive layer) on a releasable liner layer (i.e., a release liner layer), or sandwiched between two releasable liner layers (referred to as a pressure sensitive adhesive film, PSA film, pressure sensitive adhesive tape, or adhesive transfer tape).
EP 3436210, incorporated herein, describes a PSA that is particularly suitable for use in an optical substrate element according to the present invention to exhibit edging optimization properties. The pressure-sensitive adhesive constituting the pressure-sensitive layer usable in the present invention should have a storage modulus G' at 85 ℃ of less than 1.6x10 5 Pa, preferably equal to or less than 1.5Pa, more preferably between 1.0Pa and 1.5x10 5 Pa. The 85 degrees celsius corresponds to the maximum temperature that can be applied to the optical element during a typical edging step. In particular, this corresponds to the maximum theoretical value of the temperature generated by friction of the edging wheel with the lens material when aggressive conditions are used during the edging step.
Solar lenses are classified according to Tv, color (a, b)
Light transmittance (Tv) is the optical product transmittance perceived by an observer at a specified solar radiation (%). Light transmittance is preferably considered to be the amount of light provided to a user by an optical article/product. The light transmission is defined by the average transmittance value of the lens in the visible range 380 to 780nm, weighted by solar irradiance (D65) and photopic visibility function (vλ). The principle is to measure the spectral transmittance of an optical product at normal incidence at a reference point using a spectrometer.
As such, the functionalized film structure according to the invention can be tailored to define, together with the associated substrate or optical base element, different hues for sunglasses having the following different visible average transmission factors Tv:
Above 80% (referred to as class 0 or class-transparent lenses),
From 43% to 80% (known as class 1 or class sunglasses),
From 18% to 43% (known as class 2 sunglasses),
From 8% to 18% (known as class 3 sunglasses),
Less than 8% (known as class 4 sunglasses).
The optical product may include a photochromic lens, an electrochromic lens, a transparent lens, a blue light cut-off function lens, or a sun lens.
PSA coloring according to the invention
Referring to fig. 2a to 2g, in order to dye the PSA layer of the functional film structure, the present inventors propose a dyeing method realized by:
-a step of providing a functionalized optical layered structure 13 comprising:
a first element representing a first single-layer or multi-layer functional film 15
At least one pressure-sensitive adhesive layer 14 comprising at least one surface protected with a protective backing layer 17, the at least one pressure-sensitive adhesive layer having optical quality, and
-A step of colouring the at least one pressure sensitive adhesive layer with a colouring agent.
Once the protective liner layer 17 is removed from the PSA layer surface, the step of coloring the at least one pressure sensitive adhesive layer with the colorant can be accomplished by several known methods such as sublimation, ink jet printing the colorant, spraying and/or screen printing the colorant, preferably sublimation.
More preferably, the step of coloring the at least one pressure sensitive adhesive layer is a sublimation step, as illustrated in fig. 2b, wherein the colorant 12 is sublimable.
The toner printing step includes applying (outputting) a dye ink containing a sublimable dye 12 to a toner transfer support or substrate 11 (such as paper) by using an inkjet printer prior to the sublimation step.
As the sublimable dye (which contains a sublimable dye dissolved or dispersed in fine particles), three disperse dye inks of red, blue and yellow, each of which is a commercially available water-based ink, are used. These inks are respectively filled in commercially available ink cartridges for inkjet printers. The ink cartridge is installed in an inkjet printer. This printer in this embodiment is a commercially available printer.
Such a printer may be controlled such that the adjustment of the tone characteristics (hue, chroma, etc.) is handled by drawing software, CCM (computer color matching), etc. Accordingly, data regarding a desired color may be stored in a computer so that a substrate having the same color quality may be repeatedly generated as needed. The color hues (e.g., gradient patterns) are also digitally controlled, which allows the matrix to be repeatedly reproduced at the same color density as desired.
In addition, the releasable liner layer 17 of the functional film structure 13 is removed from the surface of the adjacent PSA layer 14 prior to introducing the structure into the sublimation box (as disclosed in fig. 2 b), thereby defining a PSA bare surface structure 16 comprised of the PSA layer 14, the single or multi-layer structure 15, the second releasable liner layer and/or the support film (if any) 20.
As disclosed in fig. 2b, during the sublimation step, the PSA bare surface structure 16 is in a flat form, and the substrate 11, on which the colorant 12 is pre-printed, is also in a flat form and preferably disposed above the PSA bare surface structure 16, with the colorant-printed surface of the substrate facing the PSA bare surface structure 16. The facing surfaces of the substrate 11 and PSA bare surface structure 16 are separated by a distance of less than 15mm, preferably less than 12mm and preferably greater than 5 mm. Specific support means 18, for example in the form of a cylindrical interlocking sleeve, are provided to maintain both the base body 11 and the PSA bare surface structure 16 in a flat form, parallel to each other and separated from each other by a specific distance.
Due to the heat provided by the sublimation lamps 19, which are located above the substrate 11 with the colorant or dye 12 printed on the PSA bare surface structure 16 facing downwards, and due to the vacuum provided in the sublimation enclosure 10, sublimable dye is sprayed from the substrate 11 towards the PSA bare surface structure 16 after the vapor deposition transfer dyeing process (fig. 2 b). The sublimation lamps 19 are disposed in the vicinity of the substrate 11 to heat the substrate 10 to sublimate the dye, with some lamps being disposed at upper positions in the enclosure 10 and others being disposed at lower positions. In this way, the lamp 19 is arranged in a position opposite the PSA bare surface structure 16 with respect to the substrate 1. The lamp 19 in the present embodiment is a halogen lamp, but is not limited thereto. Any lamp or the like capable of heating the substrate 11 in a contactless relationship with the substrate may be used.
The resulting PSA bare surface structure 16 (with the colorant sublimated thereon as illustrated in fig. 2 c) is covered with a strippable liner layer 17 and then transferred to the suction enclosure 21 shown in fig. 2c, while the substrate 11' losing the colorant can be discarded.
The purpose of the imbibition enclosure 7 illustrated in fig. 2d is to fix the dye to/penetrate the exposed surface structure 16 of the PSA onto which the colorant sublimates by heating, thereby obtaining a PSA colored structure 14'.
Preferably, when the PSA bare surface structure 16 covered by the releasable liner layer 17 with the colorant sublimated thereon is introduced into the imbibition tank 7, the PSA surface with the dye deposited thereon defines the upper surface of the PSA bare surface structure in the enclosure such that the dye need only be immobilized on and/or penetrate into the PSA material beneath which it is deposited with the natural assistance of gravity and without any risk of migrating to the perimeter or center of the PSA structure (because the PSA structure is planar in shape) or to the bottom surface as would be expected with the prior art method described with reference to fig. 1c (wherein the surface of the lens with the dye sublimated thereon is the lower surface in the enclosure).
With reference to fig. 3, an illustrative embodiment of the invention will be described, involving a functional film structure of the kind described in document WO 2020/002606, which is incorporated herein by reference, and shown on fig. 3 and 4a, the PSA layer of which has been coloured according to the method of the invention.
More precisely, this preferred functional film structure comprises, from top to bottom:
Reaction force cushion layer 17
An optional liner layer side slip layer 22
Colored PSA adhesive layer 14'
Functional film or HMC stack (antireflection, hardcoat, temporary grip coating cover layer, film) 15
Carrier-side sliding layer 23
Carrier layer 20
More precisely, such a functional film structure comprises a multilayer film surrounded by a carrier layer 20 and a reaction force cushion layer 17. The carrier layer 20 may be made of a composition including polyethylene terephthalate (PET). The thickness of the carrier layer 20 may be in the range of 50 μm to 500 μm. The reactive force liner layer 17 may be made of a composition including polyethylene terephthalate (PET) or Polyester (PE). The thickness may be in the range of 50 μm to 500 μm. According to a particular aspect, the reaction force cushion layer 17 comprises silicone, in particular on its side facing the carrier layer 20. The reaction force pad layer 17 may be a PPI adhesive product sold under the number PPI 0601 (0.075 mm) siliconized polyester film (SILICONISED POLYESTER FILM).
The functional film 15 extends between the carrier layer 20 and the reaction force cushion layer 17 in a predetermined receiving area. The functional film may be one layer or may be formed of a stack of layers.
The receiving area corresponds to the area immediately surrounding the functional film, which includes a space that allows any small positioning around the initial positioning of the functional film to float.
The functional film may modify the optical, transmission, or mechanical properties of the optical article. For example, the functional film may provide any one of a polarizing, tonal, or colored filter, a hardcoat function, an anti-reflective function, a protective coating and/or a surface quality function, or a combination thereof.
Preferably, the functional film 15 comprises a thermoplastic film having a haze value of preferably no more than 0.4%, which has a haze value of preferably no more than 0.4% as a whole, once removed from both the carrier layer 20 and the reaction force liner layer 17, and once the functional film is present and fixed to the optical article, removed from any protective film intended to be removed.
According to ASTM D1003-00, using a Haze Guard from BYK-GardnerHaze values are measured by light transmission measurements by a haze meter (color difference meter), which is incorporated herein by reference in its entirety. All references to "haze" values in this application pass this standard. The instrument is first calibrated according to the manufacturer's instructions. Next, the samples were placed on the transmitted beam of a pre-calibrated meter and haze values were recorded from three different sample locations and averaged.
The thickness of the functional film 15 may be in the range of 10 μm to 500 μm. The functional film 15 may be made of a composition including polyethylene terephthalate (PET) and/or polycarbonate and/or cellulose triacetate (TAC, for cellulose triacetate, france), which may be coated with a Hard Coating (HC) or an anti-reflection (AR) coating forming part of the functional film 15.
Further, the functional film 15 may generally include additional layers capable of performing some of the functions described above.
The carrier layer 20 and the reaction force cushion layer 17 are larger than the receiving area in at least one dimension and in particular larger than the functional film 15 intended to be present in the receiving area. In particular, as illustrated in fig. 3, the perimeter of the functional film layer 15 is surrounded by the perimeter of the carrier layer 20 and the perimeter of the reactive liner layer 17. In particular, this enables the carrier layer 20 to be held, fixed or clamped to a machine or device without contaminating, contaminating or stressing the functional film 15.
A carrier-side sliding layer 23 may be positioned between the carrier layer 20 and the functional film 15. The carrier-side sliding layer 23 is adapted to enable positional floating of the functional film 15 relative to the carrier layer 20. In other words, the carrier-side sliding layer 23 is adapted to reduce the radial stress to be exerted on the functional film 15 if this film is too firmly fixed to the carrier layer 20. It is contemplated that during the forming step, there is a point of maximum height from the initial plane. The radial stress described above will be estimated to extend significantly radially from the maximum height point.
The thickness of the carrier-side slide layer 23 may be in the range of 10 μm to 500 μm.
According to an embodiment, the carrier-side sliding layer 23 may include double-coated tape with product number 9088 (or also referred to as "high performance double-coated tape with adhesive 375 9088") provided by 3M company, or any equivalent product.
According to another embodiment, the carrier-side slide layer 23 may include an acrylic adhesive layer. The carrier-side slip layer may have a total light transmittance of 90% or greater, and/or a haze value of 1.0 or less. The carrier-side slip layer may have dry-wet adhesion characteristics of 25N/25mm or greater according to a test method using:
A tensiometer for the tension of the fluid,
A substrate of a corona-treated polycarbonate sheet,
-Peel angle of 90 DEG, and
Peeling speed 25mm/min
-Backing material: corona treated poly-pairs ethylene terephthalate film
Lamination conditions on polycarbonate sheet-round trip with 2kg roller.
An acrylic adhesive layer may be sandwiched between two PET release liner layers. Depending on the test method using the tensile tester, the peeling speed of 0.3m/min, and the peeling angle of 180 °, the peelability of one of the PET release liner layers may be 0.2N/50mm or less, and the peelability of the other PET release liner layer may be 1.0N/50mm or less.
The cushion layer side sliding layer 22 may be positioned in contact with the reaction force cushion layer 17 or with a layer fastened to the reaction force cushion layer 17. The cushion layer side sliding layer 22 enables positional floating of the functional film 15 with respect to the reaction force cushion layer 17. In other words, the cushion layer side sliding layer 22 is adapted to reduce radial stress to be exerted on the functional film 15 if the functional film is too firmly fixed to the reaction force cushion layer 17. It is contemplated that during the forming step, there is a point of maximum height from the initial plane. The radial stress described above will be estimated to extend significantly radially from the maximum height point.
The liner layer side slip layer 22 may be made of a composition including Polyethylene (PET). Alternatively, the cushion layer side sliding layer 22 may be made of the same or similar composition as that of the carrier side sliding layer 23 set forth above. Alternatively, the backing layer side slip layer may be a Pressure Sensitive Adhesive (PSA), according to PCT application No. WO 2017168192 filed on 3/29 of 2016, which is incorporated herein by reference. The PSA further has the property of an optical grade material having a haze value preferably no greater than 0.4%.
The liner layer side slip layer 22 may include a silicone layer on one or both sides. The thickness of the liner layer side sliding layer 22 may be in the range of 10 μm to 100 μm. In particular, the reaction force cushion layer 17 may include a silicone layer at least on a region in contact with the cushion layer side sliding layer 22.
In some examples, the carrier side slip layer 23 is a PSA, no. 8141, provided by 3M company, and the carrier side slip layer is provided with a protective slip film, no. SWT10 or SWT 10+r, provided by NITTO company (which may be removed after thermoforming). According to other examples, the carrier side slip layer 23 is a PSA, no. CS9621, provided by NITTO corporation, and the carrier side slip layer 23 is provided with a protective slip film, no. SWT10 or SWT 10+r, provided by NITTO corporation (which may be removed after thermoforming). According to other examples, the carrier side sliding layer 23 is a PSA number 9088, also referred to as a high performance double coated tape 9088 with adhesive 375, provided by 3M company.
As illustrated in the embodiment of fig. 1, the multilayer structure may also include an adhesive layer 14', such as a pressure sensitive adhesive (also referred to as PSA) layer, interposed between the functional film 15 and the cushion layer side sliding layer 22 or the reaction force cushion layer 17. The adhesive layer 14' may be made of the same or similar composition as that in the carrier-side sliding layer 23 or the cushion-layer-side sliding layer 22 set forth above. According to a preferred embodiment, the adhesive layer 14' may be a Pressure Sensitive Adhesive (PSA) according to PCT application No. EP 3436210, which is incorporated herein by reference. The PSA further has the property of an optical grade material having a haze value preferably no greater than 0.4%.
The adhesive layer 14' may be part of the liner layer side slip layer 22. For example, the adhesive layer 14' may be in direct contact with the reaction force cushion layer 17, plus a (modular) possible silicone layer.
Advantageously, in view of the lamination of the functional film 15 on the optical substrate element, before shaping the functional film, according to US application No. 2016/0216425, which is incorporated herein by reference, the surfaces of said first and second elements intended to be placed in contact with the adhesive layer 14' coloured according to the invention can be subjected, before said contact placement, to a surface treatment selected from the group consisting of a plasma treatment in an inert nitrogen atmosphere at a dose ranging from 40 W.min/m 2 to 100 W.min/m 2 and a corona treatment in ambient air at a dose ranging from 40 W.min/m 2 to 50 W.min/m 2, such that the reduction between the peel force in dry condition and the peel force in wet condition is less than or equal to 35% (inclusive).
More precisely, the surface of the reaction force cushion layer 17 or the cushion layer side sliding layer 22 or the protective cushion layer intended to be in contact with the colored PSA may be subjected to surface treatment before the contact placement, or the surface of the functional film 15 or the carrier side sliding layer 23 or the second functional film or the base optical element intended to be in contact with the colored PSA may be subjected to surface treatment.
In the example shown, the surface of the base optical element intended to be in contact with the coloured PSA is subjected to a corona treatment and the surface of the functional film 15 intended to be in contact with the coloured PSA is subjected to a surface treatment, before said contact with the PSA is placed.
In view of the lamination of the functional film 15 on the optical substrate element, the reaction-force backing layer 17 is fastened to the carrier layer 20 at least in two different regions, preferably at least three different regions, of the reaction-force backing layer 17 according to PCT application No. WO 2020002606, which is included herein by reference, before shaping the functional film. The functional film 15 is maintained between the carrier layer 20 and the reaction force cushion layer 17, but preferably has a positional float due to the carrier-side sliding layer 23 and the cushion layer-side sliding layer 22. Such fastening prior to shaping makes it possible to maintain the position of the functional film 15 in the receiving area in relation to the carrier layer 20 and the reaction force cushion layer 17 in a predetermined position significantly at least during thermoforming. For this purpose fastening means are provided, electrostatic forces generated by the properties of the material of the reaction force cushion layer 17 and/or the carrier layer 20, additional means, such as glue or adhesive, introduced between the reaction force cushion layer 17 and/or the carrier layer 20, or as a result of a process, such as thermoplastic welding, applied to the reaction force cushion layer 17 and/or the carrier layer 20. Preferably, the fastening means extends beyond the receiving area.
In addition to the fastening means, the adhesive layer may fasten the functional film 15 to the carrier layer 20 and/or the reaction force cushion layer in the receiving area. The adhesive layer may be an additional layer, adhesive layer 14', or a liner layer side slip layer or carrier side slip layer as a PSA adhesive layer. Such an adhesive layer is able to maintain the position of the functional film 15 in the receiving area in a predetermined position with respect to the carrier layer 20 and/or the reaction force cushion layer 17 before and during thermoforming, thereby further enhancing the effect of the fastening means.
The adhesive layer is an additional layer, an adhesive layer 14', and/or a backing layer-side or carrier-side slip layer as an adhesive layer, and the functional film 15 is fastened to the carrier layer 20 and/or the reaction force backing layer in the receiving area, it being the adhesive layer that is colored according to the invention.
In particular, the reaction force cushion layer 17 is configured to expand when a positive pressure is applied on the face of the carrier layer 20 opposite the reaction force cushion layer 17.
When inflated due to the pressure exerted on the carrier layer 20, the reaction force cushion layer 17 exerts a reaction force on the functional film 15 over a significant whole area of said functional film 15. Thus, delamination of some edges of the functional film 15 is limited or even prevented.
After shaping, and possibly also before shaping, the reaction force cushion layer 17 may be in contact with the carrier layer 20 for substantially every region of the reaction force cushion layer 17 that is not in contact with the functional film 15 or that does not face the receiving area. According to an embodiment, the fastening of the carrier layer 20 towards the reaction force cushion layer 17 takes place substantially entirely around the receiving zone.
According to PCT application No. WO 2020/002606, which is incorporated herein by reference, a standard thermoforming machine can be used to thermoform the multilayer film.
Furthermore, according to PCT application No. WO 2020/002606, which is incorporated herein by reference, an exhaust system may be used to prevent defects on the multilayer film 2 caused by trapped gases during thermoforming.
In the present embodiment, the reaction force liner layer 17 may be removed after the shaping in consideration of the lamination step.
In particular, laminators are used to enable lamination of functional films carried by a carrier layer onto an optical article. The laminator has a moving element adapted to bring the thermoformed functional film toward the optical article and/or to bring the optical article toward the thermoformed functional film. Thereafter, the functional film is brought into contact with an optical article. In certain embodiments, the thermoformed functional film affixed to the carrier layer takes on a convex shape and is in contact with the concave face of the optical article. In another embodiment, the thermoformed functional film affixed to the carrier layer takes on a concave shape and is in contact with the convex face of the optical article. In yet another embodiment, two thermoformable functional films, each exhibiting a concave shape and a convex shape, are brought into contact with the convex and concave faces of the optical article, respectively.
In an embodiment, a positive pressure is applied from the side of the carrier to push the functional film onto the face of the optical article.
The pressure may be maintained for a duration of between 10 seconds and 10 minutes. This makes it possible to ensure that the adhesive layer properly adheres the functional film to the optical article.
Thereafter, in some embodiments, a cooling step is applied.
Finally, the carrier layer is removed from the functional film. The carrier-side slip layer, if present, may also be removed.
After these last steps, an optical article is obtained comprising a film fixed on one of its surfaces, without defects or with reduced defects. At least the reaction force cushion layer is used, defects are prevented, and in some embodiments, additional defects may be prevented using a possible sliding layer and a possible vent.
In certain embodiments, the laminator is a thermoforming machine. In another example, the carrier layer is clamped in the same clamping system during both thermoforming and lamination. Possibly, the carrier layer may be undamped to remove the reaction force backing layer. In such a machine, a cooling step may be applied between thermoforming and lamination.
According to a particular embodiment, the silicone that may be present on the carrier layer and/or the reaction force liner layer may be a silicone having a product number SILPHAN S50 provided by Siliconature company.
According to various embodiments, the carrier side of the reaction force cushion layer may be in direct contact with the functional film or one of the layers on top of the functional film intended to be present on the optical article and intended to function the optical article.
PSA staining experiments and results
The following provides illustrative examples and some steps that illustrate the invention and key results.
Printing step
There are provided commercially available, sublimable, useful in ophthalmic articles, and compatible with selected substrate materials (e.g., polycarbonate) different inks or dyes having three primary colors, red, yellow and blue, which are typically composed of water-based solutions.
The step of printing the dye onto the transfer paper may last for 2 minutes and dry for 10 minutes according to the particular formulation.
Surface preparation
The preferred functional film structure 13 is provided with a PSA layer 14 sold by Nitto under the number EL5902RT and having a thickness of 50 microns as PSA in contact with the functional film 15 and which PSA layer is intended to be in contact with the optical substrate element after application of the preferred functional film structure to said optical substrate element. The preferred functional film structure 13 includes a multilayer functional film 15 (which is provided with a hard coating layer and an anti-reflective layer), a carrier side slip layer 23, and a carrier 20, as depicted in fig. 3.
In order to maximize the adhesion of the PSA layer 14 intended to be coloured by the sublimable dye, the two surfaces that will come into contact with the coloured PSA (i.e. the surface of the optical substrate element on which the functional film structure is intended to be applied on the one hand, and the surface of the functional film 15 of the functional film structure 13 on the other hand) and/or the two surfaces of the PSA itself will be the object of a surface treatment, such as corona treatment.
More precisely, according to the corona treatment of US application number US 2016/0216425, which is included herein by reference, is applied on the one hand on the surface of the optical substrate element intended to be in contact with the PSA layer to be coloured and on the other hand on the surface of the multifunctional film 15 comprising a hardcoat layer and an antireflection layer intended to be in contact with the PSA layer to be coloured and/or on both surfaces of the PSA itself.
Sublimation step
As disclosed in fig. 2b, the reactive liner layer 17 is removed from the PSA layer to be pigmented to obtain a PSA bare surface structure 16 comprised of the PSA layer 14, the single or multi-layer structure 15, the second releasable liner layer and/or the support film or carrier 20.
The sublimation step is carried out at a temperature of 55 ℃ in connection with the sublimation lamp, a pressure of vacuum (greater or less than 0.1 kPa), wherein the sublimation run time is 6min.
After the sublimation step, according to fig. 2c, a PSA bare surface structure 16 is obtained, on which a colouring agent sublimates, which is laid on the surface of the PSA layer.
A reactive liner layer 17 is then applied to the surface of the coloured PSA layer surface 14 to protect it during transfer to the imbibition enclosure 7 (figure 2 d).
Imbibition step
As illustrated in fig. 2d, after the imbibition step of the protected colored PSA layer surface 14 'structure in a box at 90 ℃ for 10 minutes, the sublimated colored dye or colorant is affixed to the PSA layer surface and/or penetrates the thickness of the PSA layer, thereby obtaining a PSA colored structure 14'.
After thermoforming, the reactive liner layer 17 is removed prior to application of the functional multilayer structure 15 via the PSA colored structure 14' onto the corona treated surface of the optical substrate element by lamination.
Thermoforming and lamination step
The pressure applied may reach 2 or 3 bar.
The pressurizing step is performed at a temperature applied to the film of about 25 ℃ to 80 ℃. The temperature for thermoforming may also be between 80-140 ℃, such as 100-130 ℃, such as 115-125 ℃, or about 120 ℃, with the highest temperature depending on the base film material, its thickness, and the final target curvature of the film/lens.
The pressure is maintained for a duration of between 10 seconds and 10 minutes. This makes it possible to ensure that the adhesive layer properly adheres the functional film to the optical article.
Thereafter, a cooling step is performed.
Finally, the carrier layer is removed from the functional film. The carrier-side slip layer, if present, may also be removed.
After these last steps, an optical article is obtained comprising a film fixed on one of its surfaces, without defects or with reduced defects. At least the reaction force cushion layer is used, defects are prevented, and in some embodiments, additional defects may be prevented using a possible sliding layer and a possible vent.
In this embodiment illustrated in fig. 2gβ, the functional film is applied to the convex face of a lens having a radius of curvature of 81 mm. The functional film was thermoformed to have a radius of curvature of 81 mm.
Adhesive layer 14 is a PSA adhesive sold by Nitto under the name EL5902 RT.
PSA thickness 50 μm
The reaction force liner layer is an adhesive product provided by PPI company under the number PPI 0601 (0.075 mm) siliconized polyester film (SILICONISED POLYESTER FILM).
Peel test
The peel test involved rolling a 25 x 70mm strip of pressure sensitive adhesive material onto the protective film strip. This tape (protective film + adhesive material) is glued to a planar support on which the film is pre-fixed. This test makes it possible to test the adhesion between the film and the protective film. The glass was left unchanged for at least 24 hours (at 23 ± 3 ℃,50% RH ± 10%) before stripping. The film was peeled at a speed of 2.54cm/min at a 90℃angle. At half of the test, a certain amount of water was added to the interface to measure the wet coating force. The force is expressed in N/25 mm. The software continuously measures the peel force as a function of displacement. This force was averaged over a length of 10mm to 20mm for dry and wet stripping.
The samples were then washed, coated and finally trimmed with a Kappa (trade name) trimmer. Once trimmed, the sample is inspected to determine if there are cosmetic defects, such as separation between films in the polarizing structure. When the stack exhibits defects, indicated by crosses in the 'lens manufacturing' column of the table. When the trimming does not present any defects, it is indicated by 'OK' in the same column.
Peel test and results
Two series of tests (a and B) were run with the formulations as indicated in table 1.
Table 1. Sublimation experience conditions to define the imbibition time for series a and series B, respectively.
As disclosed in table 2 below, in the first series (a), the fact whether there is a imbibition step was evaluated. Two conditions were set, no imbibition step and imbibition step during 1h at low temperature (90 ℃) where HMC stacks are known to withstand temperatures above 100 ℃) to avoid breakage of the antireflective stack on the consumable.
In the second series (B), the moderate imbibition time at 90 ℃ was tested. The peel force results show (Table 2) that 10 to 20 minutes of imbibition is sufficient to be in the safe area in terms of adhesion (dry peel force and wet peel force >20N/25 mm) and that the dry and wet adhesion are the same. The best possible value for imbibition will be around 20 minutes, at which time 25N/25mm is reached. For very dark hues (categories 3 and 4), longer bleed times may be required to fix the dye, and the skilled person can easily determine the bleed times from studies of the color change that occurs after several days compared to the initially deposited color.
Table 2 peel test results for series A and series B.
The results for the peel force of series a (table 2) show that the peel force adhesion is reduced without imbibition (16N/25 mm without imbibition versus 22N/25mm for 1h at 90 ℃), but the dry and wet peel forces are the same, which is a good result.
Figure 4 shows the peel force results for PSA (left side) and PSA + dye (other side) without dye and under dry and wet conditions at different imbibition times. The dashed line corresponds to the minimum adhesion from previous studies of lamination techniques. The solid line corresponds to the maximum adhesion of the PSA without dye.
Figure 4 shows that some adhesion was lost when the dye was sublimated onto the PSA (29N/25 mm in the absence of dye versus 25N/25mm in the presence of dye), but the adhesion of 25N/25mm obtained in the presence of dye was considered very good.
Influence of distance between PSA and transfer paper
During the sublimation step, the PSA layer 14 is in a flat form and the transfer paper is also in a flat form, allowing the distance between the two objects to be reduced and a deeper lens to be obtained with the same amount of dye in the colorant solution formulation than would be obtained if the curved lens received sublimated dye. For example, for the same amount of dye in the colorant solution formulation, tv-15% is obtained when the curved lens receives sublimated dye, and a darker color with Tv-10% is obtained when the PSA layer 14 receives sublimated dye.
This was confirmed by sublimation testing run with ink formulations according to table 3:
First sublimation with two pairs of double-plano lenses versus plano/curved lenses
Second sublimation of PSA consumables with three pairs of double flat lenses
For these tests, the imbibition time of the PSA consumable was fixed at 90 ℃ for 1h. To be able to measure the transmission spectrum of PSA consumables colored by sublimation, the PSA patches of the consumables were glued on a bi-flat optic (without non-optical elements such as carrier, liner layer. In order to avoid confusion, in table 3, PSA consumables are mentioned, even if they are glued to the bi-flat lenses for handling purposes. The "bifocal lens" in the table refers to a bifocal lens colored by sublimation using a standard sublimation method.
TABLE 3 ink formulations for demonstrating that deeper final lenses were obtained with the same amount of dye in a flat support (bi-flat lens or flat PSA film) than with a curved flat lens
The results shown in table 4 represent Tv and color (a, b) obtained on bi-flat lenses, flat/curved lenses and flat PSA consumables.
Accordingly, for the same amount of dye on the transfer paper, a darker lens (Tv between 7.5% -9.4% for a flat PSA film) is always obtained when the colorant is sublimated onto a bi-flat lens or a flat PSA film, whereas a lighter lens (Tv-15%) is obtained when a flat curved lens is used. This may be due to the fact that the transfer paper is flat and if the colorant sublimates from the flat support onto a likewise flat substrate (bi-flat lens or PSA film), the two elements can be closer together (printing paper and bi-flat lens or flat PSA film) and reduce the amount of dye on the paper required to obtain a given transmittance compared to the amount of dye required from a flat printing paper onto a curved lens by standard sublimation processes.
Dispersibility at the coloring step (hard coating-free step)
As demonstrated in tables 4 and 5 below, the dispersibility of the sublimation process step is very similar between sublimation on curved lenses and sublimation on flat PSA films.
TABLE 4 ink formulations for demonstrating the very similarity between sublimation on curved lenses or sublimation on flat PSA films for the dispersibility of the sublimation process steps
Table 5. Results of dispersibility on psa consumables and flat optical bending lenses.
Testing of different colours and surface treatments
Several prototypes of different colors have been laminated to a bi-level light and finished edging. Some samples have been edged and no edge defects were observed. Colored consumables have also been laminated to curved lenses and edging results are good.
Type of coloring
Different types of coloration can be obtained, complete and uniform coloration, gradient coloration, specific patterns such as logos or marks (obtained by using specific masks applied on the PSA surface during the sublimation step).
Advantages are that
The present invention achieves the goal of providing any sunglass color in a rapid delivery technique because the consumable is colored with a rapid coloring process (15 minutes) compared to known solutions that require about 3 hours to color the lens or film. Furthermore, the tinting of the consumable can be performed in parallel with the surface treatment of the lens, without adding additional time to the manufacturing process, and with obtaining a final hue during lamination of the functional film on the rear and/or front side of the lens, i.e. without adding specific additional steps that would prolong the lamination process.
Furthermore, the method according to the invention results in a reduced energy consumption compared to standard sublimation onto lenses, since the PSA is a soft and better dye matrix compared to lenses, the duration required for the imbibition step on the PSA layer is almost 10-20 times (imbibition at 90 ℃ for 10-20 minutes is sufficient to ensure good adhesion, whereas in standard sublimation processes the imbibition period of the dye on the lenses is between 1 hour 30 minutes and 3 hours at high temperatures of 125 ℃ to 160 ℃ to ensure penetration of the dye inside the hard lens substrate).
Furthermore, due to the present invention, the following other advantages are observed:
Lower complexity:
tool tooling simplification-only one tool tooling system optimized for flat PSA films is now required, not specific tool tooling for each lens geometry
Formulation/pattern printing is simplified regardless of the lens substrate or power. Indeed, for a given color, only one dye formulation optimized for a flat PSA film is now required, whereas conventional methods require different formulations/pattern printing, each adapted to a different optical power, to ensure uniformity between the center and the edge of the curved lens receiving sublimated dye on its curved surface.
From a quality point of view, due to the hard coating process, the metamerism between the substrate and the dispersibility is eliminated
In general, no wet chemistry is involved in the process and it is possible to automate it (in-line two-piece process).
Dye consumption is reduced due to the fact that the dye sublimation step is performed from flat paper to flat PSA film rather than to curved lenses. In fact, the distance between the flat sublimation paper and the flat film can be the same and reduced to a minimum, reducing dye consumption, since the greater the distance, the more the dye tends to migrate to other parts of the vacuum chamber (e.g. walls) than towards the support to be coloured. In addition, compared to conventional sublimation on lenses, dye loss is prevented during the imbibition step because the dye is confined between the backing layer/PSA and TAC during the imbibition step according to the invention
For a given color, only one dye formulation may be sublimated onto the same PSA layer, which layer may then be applied onto any kind of substrate. Accordingly, the same spectrum and color appearance is obtained for different substrates. In contrast, in standard sublimation processes, different dye formulations are required for different substrates because of their different chemistries and tinting capabilities (e.g., polycarbonate and 1.6 substrates). As a result, in addition to the complexity of the formulation from substrate to substrate for the same color, the spectral profile from substrate to substrate for the same color reference. This results in metamerism
In the case of sublimation onto the PSA, the color applied to the PSA is deterministic, since no further hard coating process is required (hard coating already on the film).
Claims (15)
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| EP22306136 | 2022-07-28 | ||
| EP22306136.7 | 2022-07-28 | ||
| PCT/EP2023/070176 WO2024022948A1 (en) | 2022-07-28 | 2023-07-20 | Functionalized optical layered structure, functionalized optical article, eyewear containing the same, and their methods of manufacture |
Publications (1)
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|---|---|
| CN119631010A true CN119631010A (en) | 2025-03-14 |
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Family Applications (1)
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|---|---|---|---|
| CN202380052941.7A Pending CN119631010A (en) | 2022-07-28 | 2023-07-20 | Functionalized optical layered structure, functionalized optical article, eyewear containing functionalized optical article, and method for making the same |
Country Status (6)
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| EP (1) | EP4562469A1 (en) |
| JP (1) | JP2025525049A (en) |
| CN (1) | CN119631010A (en) |
| AU (1) | AU2023316716A1 (en) |
| MX (1) | MX2025001085A (en) |
| WO (1) | WO2024022948A1 (en) |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH01277814A (en) | 1988-04-30 | 1989-11-08 | Hoya Corp | Method of dyeing plastic lens |
| JP3819178B2 (en) * | 1998-08-27 | 2006-09-06 | 株式会社ニデック | Plastic lens dyeing method |
| JP2007322571A (en) * | 2006-05-31 | 2007-12-13 | Panac Co Ltd | Optical filter |
| JP5550944B2 (en) * | 2010-02-26 | 2014-07-16 | 山本光学株式会社 | Single-lens polarized glasses |
| JP2011202012A (en) * | 2010-03-25 | 2011-10-13 | Nitto Denko Corp | Acrylic adhesive agent composition and acrylic adhesive tape |
| JP2015021995A (en) * | 2013-07-16 | 2015-02-02 | 株式会社有沢製作所 | glasses |
| FR3009234B1 (en) | 2013-08-05 | 2017-09-29 | Essilor Int | FUNCTIONALIZED LAYER STRUCTURE |
| CN109070232B (en) | 2016-03-29 | 2021-11-16 | 依视路国际公司 | Functionalized laminated optical element with improved edging resistance |
| EP3587093A1 (en) | 2018-06-28 | 2020-01-01 | Essilor International | Device and method for forming a functional film intended to be laminated on an optical article |
-
2023
- 2023-07-20 EP EP23744778.4A patent/EP4562469A1/en active Pending
- 2023-07-20 AU AU2023316716A patent/AU2023316716A1/en active Pending
- 2023-07-20 JP JP2025504702A patent/JP2025525049A/en active Pending
- 2023-07-20 CN CN202380052941.7A patent/CN119631010A/en active Pending
- 2023-07-20 WO PCT/EP2023/070176 patent/WO2024022948A1/en not_active Ceased
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2025
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Also Published As
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| MX2025001085A (en) | 2025-03-07 |
| WO2024022948A1 (en) | 2024-02-01 |
| JP2025525049A (en) | 2025-08-01 |
| AU2023316716A1 (en) | 2025-01-16 |
| EP4562469A1 (en) | 2025-06-04 |
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